US11325336B2 - Method and system for forming packages - Google Patents

Abstract

A method of forming reinforced packages. The method can comprise forming an attached web by adhering a blank to a web of material and moving the attached web in a downstream direction through at least a tube forming assembly and a carton forming assembly. The method also can comprise at least partially forming a tube by folding at least a portion of the web of material as the attached web moves through the tube forming assembly, forming a reinforcement sleeve by folding at least a portion of the blank so that the reinforcement sleeve extends at least partially around the tube as the attached web moves through the carton forming assembly, and forming a reinforced package comprising the reinforcement sleeve and a tube portion by separating the tube portion from a remainder of the tube, the reinforcement sleeve being adhered to the tube portion.

Description

CROSS-REFERENCED TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent application Ser. No. 15/142,103, filed on Apr. 29, 2016, which claims the benefit of U.S. Provisional Patent Application No. 62/179,172, filed on Apr. 29, 2015.

INCORPORATION BY REFERENCE

The disclosures of U.S. patent application Ser. No. 15/142,103, which was filed on Apr. 29, 2016, and U.S. Provisional Patent Application No. 62/179,172, which was filed on Apr. 29, 2015, are hereby incorporated by reference for all purposes as if presented herein in their entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to reinforced packages for holding products and to methods of forming the packages. More specifically, the present disclosure is directed to methods and systems for forming the packages including a reinforcing sleeve for supporting a bag.

Bags, such as paper or plastic bags, traditionally have been used for the packaging and transport of products from bulk materials such as rice or sand to larger items. Bags generally are cheap and easy to manufacture and can be formed in different configurations and sizes, and can be used for storage and transport of a wide variety of products. In particular, in the Fast Food industry, bags are frequently used for packaging of prepared food items, such as sandwiches, etc. Currently, there is a growing demand for bags or similar packages for use in packaging various products, including sandwiches, French fries, and other prepared food items, that a worker can easily open, such as with one hand, and have the bag supported in an open configuration to enhance the efficiency of packaging of such products. However, it is equally important that the costs of such bags necessarily must be minimized as much as possible. While various bag designs including reinforcing or supporting materials have been developed, often, the manufacture of such specialty bags having reinforcing layers or materials supplied thereto has required multiple stages or operations, which can significantly increase the cost of manufacture of such bags.

SUMMARY OF THE DISCLOSURE

In general, one aspect of the disclosure is directed to a method of forming reinforced packages. The method can comprise forming an attached web by adhering a blank to a web of material and moving the attached web in a downstream direction through at least a tube forming assembly and a carton forming assembly. The moving the attached web can comprise moving the blank with the web of material. The method also can comprise at least partially forming a tube by folding at least a portion of the web of material as the attached web moves through the tube forming assembly, forming a reinforcement sleeve by folding at least a portion of the blank so that the reinforcement sleeve extends at least partially around the tube as the attached web moves through the carton forming assembly, and forming a reinforced package comprising the reinforcement sleeve and a tube portion by separating the tube portion from a remainder of the tube, the reinforcement sleeve being adhered to the tube portion.

In another aspect, the disclosure is generally directed to a system for forming reinforced packages. The system can comprise an attachment assembly receiving a web of material and a blank. The attachment assembly can bring the blank into engagement with the web of material for forming an attached web. A tube forming assembly can be disposed downstream from the attachment assembly. The tube forming assembly can receive the attached web and can comprise web folding features for folding at least a portion of the web of material to at least partially form a tube. A carton forming assembly can be disposed downstream from the attachment assembly. The carton forming assembly can receive the attached web and can comprise carton folding features for folding at least portion of the blank over the tube to form a reinforcement sleeve. The system further can comprise a cutting assembly comprising cutting features for separating a tube portion from the web of material to at least partially form a reinforced package comprising the tube portion attached to the reinforcement sleeve.

Additional aspects, features, and advantages of the present invention will become apparent from the following description and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

FIG. 1 is a perspective side view of a reinforced package in a flattened condition formed according to a system and method of forming reinforced packages according to an exemplary embodiment of the disclosure

FIG. 2 is a plan view of a blank for forming a reinforcing construct of the reinforced package ofFIG. 1.

FIGS. 3 and 4 are perspective views of the reinforced package ofFIG. 1 in an opened condition.

FIG. 5 is a schematic illustration of the system and method of forming the reinforced packages ofFIG. 1 according to the exemplary embodiment of the disclosure.

FIGS. 6A-8 are perspective views of a carton feeder, an adhesive applicator, and an attachment assembly of the system ofFIG. 5 schematically showing the carton feeder, the adhesive applicator, and the attachment assembly feeding blanks and attaching the blanks to a web of material to form an attached web according to the exemplary embodiment of the disclosure.

FIGS. 9-11 are perspective views of a tube forming assembly of the system ofFIG. 5 schematically showing the tube forming assembly forming a tube of the web of material according to the exemplary embodiment of the disclosure.

FIGS. 12 and 13 are perspective views of a carton forming assembly of the system ofFIG. 5 schematically showing the carton forming assembly folding the blanks over the tube according to the exemplary embodiment of the disclosure.

FIGS. 14 and 15 are perspective views of a heat sealer assembly of the system ofFIG. 5 schematically showing the heat sealer assembly forming a transverse seal in the tube according to the exemplary embodiment of the disclosure.

FIG. 16 is a schematic side view of the heat sealer assembly ofFIGS. 14 and 15.

FIGS. 17 and 18 are perspective views of a cutter assembly and a conveyor assembly of the system ofFIG. 5 schematically showing the cutting of the attached web into individual reinforced packages according to the exemplary embodiment of the disclosure.

FIG. 19 is a perspective view of a carton feeder according to an alternative embodiment of the disclosure.

FIG. 20 is a schematic illustration of a system and method of forming the reinforced packages ofFIG. 1 according to the a further alternative embodiment of the disclosure

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure generally relates to a system and method of forming reinforced packages for holding products such as food products or other articles. Packages according to the present disclosure can accommodate articles of any shape. The packages can comprise a bag or liner comprising a relatively flexible material attached to a reinforcing construct comprising a relatively rigid material (e.g., paperboard). The bags can generally be made from a paper, plastic, laminate, or other stock material and can be attached to the reinforcing construct that can be located between the opened end and sealed or closed end of the bag. In one embodiment, the bags comprise polyethylene material or any other suitable heat-sealable material. The reinforcing construct can be of varying widths and can extend about or over the closed ends of the bags, in some embodiments enclosing such closed ends, and will provide support for the bags upon loading with a product or article or series of articles therein. In some embodiments, the reinforcing constructs can be folded with their bags into a configuration supporting the bags in a freestanding, upright, and opened condition for ease of loading.

FIG. 1 illustrates a reinforced package generally indicated at1 that can be formed by one embodiment of the system and method of the present disclosure. Thepackage1 includes abag3 and a reinforcing construct orsleeve5 attached to thebag3. The bag has an open end7, a closed end9 (FIG. 3), and aninterior space17 for holding a product. In one embodiment, thebag3 has gussetedsides60 including a fold line61 (FIGS. 3 and 4) extending the length of the bag on each side to facilitate forming the gusseted side. Thegussets60 can extend between a central portion63 (e.g., the front of the bag3) and respectivemarginal portions65,67, which can form the back of thebag3. In the illustrated embodiment, themarginal portions65,67 can be at least partially overlapped with one another and adhered to one another to form alongitudinal seam71 extending along the height of the bag3 (FIG. 4). As shown inFIG. 3, the closedend9 can be at least partially closed by a transverse seal orseam69 where the walls (e.g., thegussets60, thecentral portion63, and themarginal portions65,67) have been heat sealed and/or adhered together along a section of thebag3. Theinterior space17 may be accessible through anotch15 in thebag3. The reinforcingsleeve5 is configured to at least partially receive aportion11 of the closedend9 of thebag3. Alternatively, the reinforcingsleeve5 could be positioned to extend around the middle portion or top portion of thebag3 without departing from the disclosure.

FIG. 2 illustrates a blank10 for forming the reinforcingsleeve5. The blank has a lateral axis L1 and a longitudinal axis L2. In the illustrated embodiment, the blank10 has afront panel21 foldably connected to afirst side panel28 at a firstarcuate fold line33. Thefirst side panel28 includes twoindividual panel portions28A,28B foldably connected to one another at alateral fold line26. Afirst back panel23 is foldably connected to thefirst side panel28 at a secondarcuate fold line31. Asecond side panel29 is foldably connected to thefront panel21 at a thirdarcuate fold line35. Thesecond side panel29 includes twoindividual panel portions29A,29B foldably connected to one another at alateral fold line27. Asecond back panel25 is foldably connected to thesecond side panel29 at a fourtharcuate fold line37. In the illustrated embodiment, the arcuate fold lines31,33 are spaced apart from thelateral fold line26 and are concave with respect to thelateral fold line26. Similarly, the arcuate fold lines35,37 are spaced apart from thelateral fold line27 and are concave with respect to thelateral fold line27. In alternative embodiments, the blank10 can have alternative panel, fold line, and/or panel portion arrangements. U.S. patent application Ser. No. 13/826,937, filed Mar. 14, 2013, is incorporated by reference herein for all purposes, and illustrates various reinforced packages including various reinforcingconstructs5,blanks10, andbags3 that can be formed from the method and system of the present disclosure.

In the illustrated embodiment, the blank10 can include one or moreadhesive regions41,43, and45 on thefirst back panel23,front panel21, and/orsecond back panel25, respectively, for receiving adhesive and being fixedly attached to an exterior surface of thebag3. Furthermore, the blank10 has afirst edge52 and asecond edge53 extending in the longitudinal direction L2. In one embodiment, theadhesive regions41,43,45 are separated from thefirst edge52 by a first distance D1 and are separated from thesecond edge53 by a second distance D2. In one embodiment, the first distance D1 is less than the second distance D2. The first andsecond side panels28,29 and regions separate from theadhesive regions41,43,45 may be generally free from adhesive in some embodiments, or may include adhesive in alternative embodiments. Additionally, the first and second distances D1, D2,adhesive regions41,43,45, and/oredges52,53 can be otherwise arranged, shaped, modified, or omitted without departing from the scope of this disclosure. For example, the first distance D1 and the second distance D2 could be generally equal or the first distance D1 could be greater than the second distance D2.

Generally, the blank10 may be folded aboutfold lines26,27 to create the reinforcingsleeve5. For example, distal ends55,57 of the first andsecond back panels23,25 may be overlapped, and thesleeve5 attached to thebag3 as illustrated inFIGS. 1, 3, and 4. In one embodiment, the glue regions or another adhesive can extend into one or both of the distal ends55,57 so that the overlapped portions of theback panels23,25 are adhered to one another when thereinforcement sleeve5 is formed. Theindividual panel portions28A,28B,29A, and29B may be in face-to-face registration in a first, non-erect position of thebag3 as illustrated inFIG. 1. The first, non-erect position illustrated reduces and/or minimizes a volume of theinterior space17 such that thepackage1 is in a non-erect or flattened state. The non-erect state may facilitate easy stacking of a plurality of packages into, for example, a shipment container and subsequent organization at a destination facility. Theindividual panel portions28A,28B,29A, and29B may be flexed or positioned to form first andsecond sides58,59 of thepackage1 in a second, erect position of thebag3 as illustrated inFIGS. 3 and 4. The second, erect position illustrated increases and/or maximizes a volume of theinterior space17 such that thepackage1 is in an erect or self-supporting state. Theclosed end9 of thebag3 can extend upwardly into an interior56 of thesleeve5 in the direction of arrow A1 while the package is in the erect state (FIG. 3). Furthermore, thebottom edge53 forms a support when thepackage1 is in the erect state for contacting a surface S (FIG. 4). The support formed of thebottom edge53 maintains the package in an upright position on the surface S. As further illustrated inFIGS. 3 and 4, thegusseted sides60 of thebag3 may be maintained extended when thepackage1 is in the erect state. Other intervening states of thepackage1 including intermediate states whereby thepackage1 is not fully erected are also applicable according to some embodiments. Furthermore, additional reinforcing sleeves of differing configurations are also applicable according to some embodiments. The reinforcedpackage1 may be otherwise shaped, arranged, and configured without departing from the disclosure.

FIG. 5 generally illustrates an example embodiment of a system andmethod100 for forming the reinforced packages (e.g., reinforced packages1) in accordance with the disclosure. In the illustrated embodiment, thepackaging system100 attaches a web ofmaterial101 for forming thebags3 of thepackages1 to theblanks10, and the attached blanks and web move through a respective packaging system from anupstream end103 to adownstream end105 generally in a machine direction M (e.g., the downstream direction), and are formed into the individual packages by various portions and components of the system as discussed further below.

As illustrated inFIG. 5, in the system andmethod100 for manufacturing reinforcedpackages1, the web ofbag material101, which can include preprinted or imprinted paper, polyethylene, laminates, or other material including flexible and heat-sealable materials, for example, is fed from a roll orsupply102. In one embodiment, thebag material101 can be pre-printed with various designs, lettering, labels and/or other graphics and can be perforated, printed roll stock that can include patterned adhesive that is positioned to facilitate forming theweb101 intobags3 in the formed packages1.

In one embodiment, acarton feeder107 is positioned at theupstream end103 of thesystem100 and includes astack108 ofcarton blanks10 that are fed to ablank conveyor109. As shown inFIGS. 6A and 6B, thecarton feeder107 is a pick and place type carton feeder that includes anarm110 withsuction cups110aor any other suitable actuator for holding a blank10. As shown inFIG. 6A, thearm110 is positioned adjacent a blank10 in thestack108 and thesuction cups110acan engage the blank10 (e.g., with vacuum pressure) so that thearm110 can carry the blank. As shown inFIG. 6B, thearm110 can be moved to the position shown inFIG. 6B so that thearm110 removes the blank10 from thestack108 and transfers it to theblank conveyor109. The suction cups110acan release the blank10 on theblank conveyor109, theplacement arm110 can move back to the position shown inFIG. 6A to retrieve another blank10, and theblank conveyor109 can move theblanks10 in the machine direction M towards theweb101 of bag material. The carton feeder could comprise other types of feeders such as mechanisms that conveyblanks10 directed from a blank cutting station, or any other suitable types of feeders or other mechanisms without departing from the disclosure.

As shown inFIGS. 6A, 6B, and 7, theblank conveyor109 includes two spaced apart lug belts or tracks111 withlugs113 for engaging a series ofblanks10 and conveying the blanks in the machine direction M. In the illustrated embodiment, thelug belts111 can be endless belts, each with a plurality of thelugs113 spaced along the respective belt. In one embodiment, thelugs113 can be spaced on thelug belts111 by approximately the height of thebags3 in the reinforced packages1. Theblank conveyor109 receives theblanks10 from the carton feeder107 (FIG. 6B) and moves the series ofblanks10 from thecarton feeder107 to anattachment assembly115 of thepackaging system100 wherein the web ofmaterial101 is attached to theblanks10 by adhesive. As shown inFIG. 7, theblank conveyor109 can include one ormore brushes114 or other suitable features that can engage theblanks10 as thelug belts111 move theblanks10 past thebrushes114. Accordingly, as thelug belts111 move theblanks10 downstream, thebrushes114 can drag against theblanks10 and push the blanks against the respectivelyadjacent lugs113 so that, for example, theblanks10 can be properly positioned for attachment to the web ofmaterial101 in theattachment assembly115. Subsequently, thelugs113 can push therespective blanks10 toward theattachment assembly115 overcoming the resistance of thebrushes114.

In the illustrated embodiment, theattachment assembly115 of thesystem100 includes an adhesive applicator116 (FIGS. 5-8) for applying adhesive to the blanks10 (e.g., at the adhesive region43). In one embodiment, theadhesive applicator116 can include one or moreadhesive outlets116amounted on aframe116babove theblank conveyor109 so that theadhesive applicator116 can apply an adhesive (e.g., adhesive118 shown schematically inFIGS. 6A and 8) to the upper surfaces of theblanks10 as they pass under theadhesive applicator116 and prior to engaging theblanks10 with the web ofmaterial101. As shown inFIG. 8, the web ofmaterial101 can be unrolled from theroll102 over one or more rollers and directed to move in the machine direction over (e.g., generally parallel to) thelug belts111 so that the web ofmaterial101 can be brought into contact with theblanks10 in theattachment assembly115. In the illustrated embodiment, theattachment assembly115 can include an adhesive compression nip roller117 (FIGS. 5 and 8) downstream from theadhesive applicator116 over the web ofmaterial101. An opposing nip roller or other surface (not shown) can be disposed below theblanks10. Accordingly, the nip rollers can receive the web ofmaterial101 and theblanks10 and press the web ofmaterial101 against theblanks10 to adhesively attach the web to the blanks via the adhesive118, for example. In one embodiment, thenip roller117 and the opposing roller can be disposed between thelug belts111 so that thelugs113 can pass by the rollers. The blank10 can be attached to theweb101 by other suitable mechanisms without departing from the disclosure.

In one embodiment, as schematically shown inFIG. 5, theweb101 withblanks10 attached (hereinafter the attached web W′) travels from theblank conveyor109 through a series ofrollers121,123 and to atube forming assembly125 of thesystem100. Thetube forming assembly125 can include web folding features for forming the web ofmaterial101 into an open-endedtube101′. In one embodiment, as shown inFIGS. 5 and 9-11, thetube forming assembly125 can include a formingroll126, guiderollers128a, an inner formingplate129, and twoouter guide plates130 that form and shape theweb101 into thetube101′ having theside gussets60 and fold lines61 (FIGS. 3 and 4). As shown inFIG. 9, the formingroll126 can engage thecentral portion63 of the web ofmaterial101, and themarginal portions65,67 of the web ofmaterial101 can fold upwardly at the formingroll126 to theguide rollers128a. In the illustrated embodiment, theguide rollers128acan direct themarginal portions65,67 over the inner formingplate129 and between theouter guide plates130.Additional guide rollers128b(FIG. 10) downstream from theguide rollers128acan further direct themarginal portions65,67 to overlap one another on the inner formingplate129. In one embodiment, the inner formingplate129 can be spaced apart from thecentral portion63 of the web of material so that thegusset portions60 extend generally vertically between thecentral portion63 and the respectivemarginal portions65,67 and adjacent to the respectiveouter guide plates130. Accordingly, themarginal portions65,67 of the web ofmaterial101 are engaged between the inner formingplate129 and theguide rollers128a,128bto move the marginal portions from being generally planar with the central portion63 (e.g., upstream from the forming roll126) to being at least partially overlapped with one another and extending over thecentral portion63 downstream from theguide rollers128a.

As shown inFIG. 10, thetube forming assembly125 includes aweb adhesive applicator127 that applies adhesive (e.g., an adhesive72 schematically shown inFIG. 10) to theweb101 as the web is being formed into thetube101′. The adhesive72 can be applied to one or both of themarginal portions65,67 by theadhesive applicator127 as they are overlapped to form alongitudinal seam71 in thetube101′ (FIGS. 10 and 11). As shown inFIG. 4, thelongitudinal seam71 can form a back of thebag3 in the formedpackage1. Theseam71 could be otherwise formed without departing from the scope of the invention. As shown inFIG. 11, thegussets60 of thetube101′ can be formed by the inner formingplate129, theouter guide plates130, and aflexible plate132 disposed downstream from the inner forming plate and the outer guide plates. In one embodiment, the inner formingplate129 can be angled downwardly so that the upstream end of the inner forming plate129 (FIG. 9) is spaced farther from thecentral portion63 of the web ofmaterial101 than the downstream end of the forming plate (not shown). Additionally theouter guide plates130 can each include an inwardly-directlyhorizontal plate130a(FIGS. 9-11), and theouter guide plates130 with thehorizontal plates130acan be angled inwardly so that theouter guide plates130 are spaced farther apart from one another at the upstream end (FIG. 9) of the outer guide plates than at the downstream end (FIG. 11) of the outer guide plates. Accordingly, in one embodiment, as the attached web W′ moves in the machine direction M, the inner formingplate129 can lower the overlappedmarginal portions65,67 and thelongitudinal seam71 toward thecentral portion63 of thetube101′ while thehorizontal plates130apush thegusset portions60 of thetube101′ inwardly. As shown inFIG. 11, as thetube101′ moves downstream from the inner formingplate129 and theouter guide plates130, the portions of thegussets60 adjacent the respectivemarginal portions65,67 overlap the portions of thegussets60 adjacent thecentral portion63 between thecentral portion63 and the respectivemarginal portions65,67. Theflexible plate132 can apply downward pressure on thetube101′ to help form the fold lines of thegussets60, to help adhere themarginal portions65,67 together via the adhesive72, and/or to generally flatten thetube101′. Thetube forming assembly125 could be otherwise configured without departing from the disclosure.

In one embodiment, the attached web W′ moves from thetube forming assembly125 to acarton forming assembly131 of thesystem100. In one embodiment, thecarton forming assembly131 includes carton folding features (FIGS. 12 and 13) that position the various flaps and panels of the blank10. In addition, thesystem100 can include folders (not shown) for breaking the fold lines of the blank10 (e.g., the arcuate fold lines31,33,35,37) between thetube forming assembly125 and thecarton forming assembly131. In one embodiment, thecarton forming assembly131 includes a carton adhesive applicator135 (FIG. 12) that applies adhesive (e.g., an adhesive136 shown schematically inFIG. 12) to the blank10 (e.g., atadhesive regions41,45—FIG. 2) so that panels (e.g., thefirst back panel23 and the second back panel25) can be overlapped and adhered (FIG. 13) to form the blank10 into thereinforcement sleeve5 as the attached web W′ moves through thecarton forming assembly131. In the illustrated embodiment, thecarton forming assembly131 can include folding plates includingouter wedge plates133a,inner guide plates133b, and formingplates134. As shown inFIG. 12, theinner guide plates133bcan extend over the blank10 (e.g., adjacent and inward of thelateral fold lines26,27—FIG. 2), and theouter wedge plates133acan push theback panels23,25 of the blank upwardly to extend generally vertically between the respectiveouter wedge plates133aand the respectiveinner guide plates133b, folding the blank10 at thelateral fold lines26,27 in one embodiment. As shown inFIG. 13, the formingplates134 can have an inner edge that is angled inwardly to further fold theback panels23,25 downwardly over thetube101′. Additionally, the formingplates134 can press theback panels23,25 against the tube so that the adhesive136 can attach the back panels to the tube. In one embodiment, theback panels23,25 can at least partially overlap and can be adhered to one another. Thecarton forming assembly131 could be otherwise configured without departing from the disclosure. For example, thecarton forming assembly131 could use forming belts instead of or in addition to the folding plates shown inFIGS. 12 and 13.

As shown inFIGS. 5 and 14-16, the attached web W′ moves from thecarton forming assembly131 through twodrive rollers135,137 and into a rotarybag sealer assembly139 that is downstream from the drive rollers. In one embodiment, the attached web W′ moves upward from thedrive rollers135,137 to the rotarybag sealer assembly139 that includes aheat seal roller141 and aheat seal arm143. In one embodiment, theroller141 has a square or other suitable polygonal cross-sectional shape (shown schematically inFIG. 16) so that the roller includes fouredges144 or corners around the circumference of the roller. Alternatively, the roller could have any suitable number of edges without departing from the disclosure. As the attached web W′ moves upward from therollers135,137, theroller141 rotates and theedges144 move into engagement with a respective section of the attached web corresponding to the bottomtransverse seal69 at theclosed end9 of thebag3. Theheat seal arm143 is urged against theroller141 and rides along the square shaped outer surface of the roller. As thecorresponding edges144 of the roller bring the corresponding section of the attached web W′ into engagement with theheat seal arm143, the arm moves away from theroller141 but stays in contact with the roller to heat the web material and join the two layers of overlapped material at the section of thetube101′ to form thetransverse seal69. In one embodiment, the heat from theheat seal arm143 can activate a previously-applied heat-activate glue and/or at least partially melt or weld the walls of thetube101′ together to form thetransverse seal69.

In the illustrated embodiment, the sequentialtransverse seals69 disposed between each of thereinforcement sleeves5 on the attached web W′ moving downstream from theroller141 can formtube portions147 in thetube101′. In one embodiment, thetube portions147 can extend from onetransverse seal69 to another and can generally correspond to thebags3 in thepackages1. The size of theroller141 can be adjusted to change the distance between the respective edges to adjust to location of thebottom seal9 of thebag3 based on the size of the bag needed. As shown inFIGS. 15 and 16, theseal arm143 is generally arcuate with a curvedinterior surface146 that contacts the web ofmaterial101 and presses the web of material against arespective edge144. After leaving the rotarybag sealer assembly139, the attached web W′ includes a series of formed reinforced packages (e.g., including thereinforcement sleeves5 attached to thetube portions147, which generally correspond to thebags3 in the separate packages1) that are connected together via thetube101′. The rotarybag sealer assembly139 could be otherwise shaped, arranged, configured, and/or omitted without departing from the disclosure. For example, thesealer assembly139 could include rollers with a generally cylindrical body having a series of raised heating elements arranged at spaced locations about the circumference of the roller so that the bottomtransverse seals69 of thebags3 are provided by pressing the portion of the attached web W′ against the raised heating elements.

As shown inFIGS. 5 and 17, thesystem100 includes a cuttingassembly151 with one or more cutting features downstream from the rotarybag sealer assembly139. In the illustrated embodiment, the cutting assembly is arotary cutting assembly151 that includes a cuttingroller153 and abase roller155 that cut the attached web W′ into the individual reinforcedpackages1. The attached web W′ is cut and separated intoindividual packages1 by cutting theweb material101 at the location corresponding to the top edge7 of thepackage1 and the location corresponding to thebottom edge9 of the package (e.g., adjacent the transverse seal69). In one embodiment, the cuttingroller153 can have anedge157 or other cutting feature that is configured to cut thetube101′ after thetransverse seam69 of atube portion147 passes the cuttingroller153 so that the cut is made just upstream fromtransverse seam69. After the cut, thepackage1 is now separated from the remainder of the attached web W′ and thetube portion147 is now thebag3. The attached web W′ can be cut and formed into thepackages1 by other mechanisms without departing from the disclosure. Further, therotary cutting assembly151 could be otherwise shaped, arranged, and/or configured without departing from the disclosure.

As shown inFIGS. 17, and 18, aconveyor assembly161 is located downstream of the rotarybag sealer assembly139 and the cuttingassembly151 to transport theseparate packages1 for collection and further handling and/or packaging for shipping to a customer. In one embodiment, theconveyor assembly161 can include several belts driven by and guided by rollers to move thepackages1 away from the cuttingassembly151 and to output the packages onto a stack or another conveyor, for example. Thepackages1 could be otherwise moved away from the cuttingassembly151 without departing from the disclosure.

In an alternative embodiment, as shown inFIG. 19 thecarton feeder107 could be replaced by a belt drivencarton feeder107′ that conveys a blank10 from the stack at relatively higher speeds than the pick and placetype carton feeder107 ofFIGS. 6A and 6B. In the illustrated embodiment, thecarton feeder107′ can move theblanks10 from thestack108 between an upper series ofbelts171 and a lower series ofbelts173. Thebelts171,173 can be endless belts that extend around and are driven by a plurality ofrollers175, for example. Thecarton feeder107′ can be timed to output a blank10 onto thelug belts111 ahead ofrespective lugs113, and a drag feature (e.g., thebrushes114 shown inFIGS. 7 and 8) can engage the blank10 until theadjacent lugs113 move downstream and engage an edge of the blank. As described above, thelugs113 can then move the blank10 downstream to theadhesive applicator116. Theblanks10 could be otherwise fed to theblank conveyor109 without departing from the disclosure. For example, the carton feeder could include a shuttle feeder or other suitable features.

FIG. 20 is a schematic view of asystem200 of a second embodiment that is similar to thesystem100 of the first embodiment. Thesystem200 is for forming the reinforcedpackages1 in a similar manner as thesystem100 exceptsystem200 includes adifferent sealing mechanism203 for forming thetransverse seals69 the bottom ends9 of thebags3. Accordingly, like or similar references numbers are used to indicate like or similar features of the two embodiments. In the embodiment ofFIG. 20, the rotary bag sealer assembly139 (FIGS. 5 and 14-16) has been removed and replaced with thesealing mechanism203 that heat seals thebottom end portions9 of thebags3 after the attached web W′ has been separated at therotary cutting assembly151. Separated but unsealedpackages210, includingreinforcement sleeves5 attached torespective tube portions147, can be fed to thesealing mechanism203 and thebottom end portions9 of the bags can be heat sealed to form the transverse seals69 (FIG. 3) of the reinforced packages1. Theheat sealing mechanism203 can be any suitable heat sealer machine for heat sealing thebag material101, or any other suitable mechanism for forming thetransverse seal69 of thebag3.

Thesystem100,200 for forming the reinforcedpackages1 of the present disclosure form the packages in a highly efficient manner by first attaching theweb101 to theblanks10 to form the attached web W′, and then forming thetube101′ from theweb101 including theside gussets60 on each side of the tube. The blank10 is then folded to form the reinforced construct orsleeve5. The attached web W′ including thetube101′ and thesleeves5 is then further processed to form the bottomtransverse seal69 of the bags and to cut and separate the attached web into individual reinforcedpackages1. Thesystem100,200 of the present disclosure is more efficient than other systems that separately form thebags3 and attach the formed bags to the blanks at least because once theblanks10 are attached to theweb101 to create the attached web W′ of thesystems100,200 of the present disclosure, the blanks move with theweb101 in an aligned manner and twisting or turning of the blanks during processing is prevented by the secure attachment to the web. Furthermore, alignment of theseparate blanks10 and formedbags3 is no longer needed as thepackages1 formed by thesystems100,200 are formed from the attached web W′ including theblanks10 attached to theweb101.

Generally, as described herein, bags can be formed from a paper stock material, although various plastic or other bag materials also can be used, and can be lined or coated with a desired material. The reinforcing sleeves described herein can be made from a more rigid material such as a clay-coated natural kraft (“CCNK”). Other materials such various card-stock, paper, plastic or other synthetic or natural materials also can be used to form the components of the packages described herein.

In general, the blanks of the present disclosure may be constructed from paperboard having a caliper so that it is heavier and more rigid than ordinary paper. The blank can also be constructed of other materials, such as cardboard, or any other material having properties suitable for enabling the carton to function at least generally as described above. The blank can be coated with, for example, a clay coating. The clay coating may then be printed over with product, advertising, and other information or images. The blanks may then be coated with a varnish to protect information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks. The blanks can also be laminated to or coated with one or more sheet-like materials at selected panels or panel sections.

As an example, a tear line can include: a slit that extends partially into the material along the desired line of weakness, and/or a series of spaced apart slits that extend partially into and/or completely through the material along the desired line of weakness, or various combinations of these features. As a more specific example, one type tear line is in the form of a series of spaced apart slits that extend completely through the material, with adjacent slits being spaced apart slightly so that a nick (e.g., a small somewhat bridging-like piece of the material) is defined between the adjacent slits for typically temporarily connecting the material across the tear line. The nicks are broken during tearing along the tear line. The nicks typically are a relatively small percentage of the tear line, and alternatively the nicks can be omitted from or torn in a tear line such that the tear line is a continuous cut line. That is, it is within the scope of the present disclosure for each of the tear lines to be replaced with a continuous slit, or the like. For example, a cut line can be a continuous slit or could be wider than a slit without departing from the present disclosure.

In accordance with the exemplary embodiments, a fold line can be any substantially linear, although not necessarily straight, form of weakening that facilitates folding there along. More specifically, but not for the purpose of narrowing the scope of the present disclosure, fold lines include: a score line, such as lines formed with a blunt scoring knife, or the like, which creates a crushed or depressed portion in the material along the desired line of weakness; a cut that extends partially into a material along the desired line of weakness, and/or a series of cuts that extend partially into and/or completely through the material along the desired line of weakness; and various combinations of these features. In situations where cutting is used to create a fold line, typically the cutting will not be overly extensive in a manner that might cause a reasonable user to incorrectly consider the fold line to be a tear line.

The above embodiments may be described as having one or more panels adhered together by glue during erection of the carton embodiments. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.

The foregoing description of the disclosure illustrates and describes various embodiments. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are within the scope of the disclosure as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure.

Claims (10)

What is claimed is:

1. A system for forming reinforced packages, the system comprising:

an attachment assembly receiving a web of material and a paperboard blank, the attachment assembly bringing the paperboard blank into engagement with the web of material for forming an attached web;

a tube forming assembly disposed downstream from the attachment assembly, the tube forming assembly receiving the attached web and comprising web folding features for folding at least a portion of the web of material to at least partially form a tube;

a carton forming assembly disposed downstream from the attachment assembly, the carton forming assembly receiving the attached web and comprising carton folding features for folding at least portion of the paperboard blank over the tube to form a reinforcement sleeve, the reinforcement sleeve comprising the paperboard blank; and

a cutting assembly downstream from the tube forming assembly and the carton forming assembly, the cutting assembly comprising cutting features for separating a tube portion from the web of material to at least partially form a reinforced package comprising the tube portion attached to the reinforcement sleeve.

2. The system ofclaim 1, further comprising a sealer assembly for forming a transverse seal in the tube, the sealer assembly comprising a heat seal roller and a heat seal arm, the heat seal roller rotating relative to the heat seal arm.

3. The system ofclaim 2, wherein the heat seal roller comprises at least one edge, the heat seal arm comprises a curved surface disposed proximate the heat seal roller so that the at least one edge slides along the curved surface as the heat seal roller rotates for pressing a section of the tube between the at least one edge and the curved surface.

4. The system ofclaim 3, wherein the at least one edge comprises a plurality of edges and the heat seal roller comprises a polygonal cross-section.

5. The system ofclaim 1, further comprising a blank conveyor for moving the paperboard blank to the attachment assembly, the blank conveyor comprising at least one lug belt with at least one lug for engaging the paperboard blank and moving the paperboard blank toward the attachment assembly.

6. The system ofclaim 5, further comprising an adhesive applicator, wherein the blank conveyor is for moving the paperboard blank at least partially through the adhesive applicator and the attachment assembly, and the attachment assembly comprises at least one nip roller, the adhesive applicator being for applying adhesive to the paperboard blank and the at least one nip roller being for pressing the paperboard blank with the adhesive against the web of material as the blank conveyor moves the paperboard blank through the adhesive applicator and the attachment assembly.

7. The system ofclaim 1, wherein web forming features of the tube forming assembly comprise two guide rollers and an inner forming plate at least partially extending over a central portion of the web of material, the two guide rollers being for guiding respective marginal portions of the web of material over the inner forming plate so that the marginal portions at least partially overlap to form the tube.

8. The system ofclaim 7, wherein the tube forming assembly further comprises a forming wheel disposed upstream from the two guide rollers and the inner forming plate, the forming wheel being for at least partially engaging the central portion of the web of material during at least a portion of the folding the marginal portions of the web of material.

9. The system ofclaim 1, wherein the carton forming assembly comprises an adhesive applicator for applying carton adhesive to two back panels of the paperboard blank and folding plates for folding the two back panels relative to a front panel of the paperboard blank and positioning the two back panels against the tube.

10. The system ofclaim 1, wherein the cutting assembly comprises a cutting roller for cutting the tube.

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